JP4238641B2 - Wood powder exterior resin floor - Google Patents

Description

【００７１】
表１は風速試験を示す。
【００７２】
【発明の効果】
オレフィン系樹脂が主体であるので、リサイクルが容易になった。特に、樹脂基材と化粧基材をポリプロピレン樹脂でそろえると同一系樹脂の為リサイクルしやすい。
【００７３】
また、リサイクルが困難な場合でも焼却しても問題が生じなくなった。
【００７４】
また、耐候性が良いので、屋外での劣化が遅くなり、落下物対策として耐衝撃性も向上したベランダ以外に庭の踏み石等の用途に使っても良い。
【００７５】
なお、本願発明においては異形成形機による製造も可能であり、この場合には押出しながら、もしくは押出した後、一液湿気硬化型接着剤によるラッピング加工してさらに後、単位長さに切断し、更に、実加工や溝加工をルーターを使って加工することも可能であり、それにより排水性を維持させながら量産性を向上できる。
【００７６】
また、エチレン−プロピレン共重合ゴム微粒子を配合することも可能であり、この場合、例えばホモポリプロピレン系樹脂５０〜９５重量％に平均粒径０．１〜０．５μｍのエチレン−プロピレン共重合ゴム微粒子が５〜５０重量部まぜる様な構成だと、切削性や歩行感が良くなるとともに、真夏の直射日光により表面温度が６０や７０℃程度になっても熱収縮を吸収する為寸法安定性が増す。
【００７７】
しかも、エチレン−プロピレン共重合体ゴム微粒子の優れた弾性作用により厳冬期でも適度な弾性が有り、更に、エントロピー弾性により間夏の直射日光の下でも適度な弾性を保つことが出来る。
【００７８】
支持体部の形状を下に凸にするので下向きに揚力が働き台風等でもめくれあがり難くなるとともに、この場合に施行面と支持体部との間に隙間が出来るので、ベランダ等の施行面に対して簡易施工出きるのでリフォームが簡単になった。
【図面の簡単な説明】
【図１】本願発明の木粉外装樹脂板の一実施例の部分概略断面図である。
【図２】図１の一実施例の全体概略断面図である。（但し、プライマー層と反応型ホットメルト接着剤は省略）
【図３】本発明の木粉外装樹脂床の下方に凸状の湾曲形状の概念断面図である。
【図４】本発明の木粉外装樹脂床の翼型の説明図である。
【符号の説明】
１ 樹脂系床材
２ プライマー層
３ 着色下台
４ 絵柄インキ層
５ アンカー剤層
６ 透明上台
７ 表面保護層
８ 化粧基材層
９ 反応型ホットメルト接着剤[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an exterior resin floor used for a veranda such as a house, an apartment, an apartment, and a garden. Furthermore, the present invention relates to a wood powder exterior resin floor that can be easily reformed, is light, has impact resistance, and is warm even when touched.
[0002]
Further, the present invention relates to a wood powder exterior resin floor such as a veranda tile that is difficult to be blown by strong winds such as typhoons.
[0003]
[Prior art]
Conventionally, exterior resin floors in which a pattern is transferred, directly printed, and a printed sheet is pasted on a veranda tile with a stone or a piece of wood pasted on the resin floor surface or a resin floor base material obtained by injection molding have been known.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-61151
In Patent Document 1, a 0.2 mm acrylic resin film with a 40 μm UV curable resin wear layer is attached to an acrylonitrile-butadiene-styrene copolymer (hereinafter referred to as ABS) base material. There was a floor unit material (corresponding to the wood powder exterior resin floor in the present application). This does not include wood flour.
[0006]
In the embodiment, there is a description of using polypropylene (hereinafter referred to as PP), polyethylene (hereinafter referred to as PE), and ethylene-vinyl acetate copolymer (hereinafter referred to as EVA) instead of ABS.
[0007]
[Patent Document 2]
Japanese Patent Laid-Open No. 2000-291246
Patent Document 2 describes a structure that simplifies the leg structure of the resin base material and aims for mass productivity. However, the cross-sectional shape of the support portion that is a portion excluding the leg portion is a flat plate shape.
[0009]
[Patent Document 3]
JP 2000-248721 A [0010]
Patent Document 3 has a veranda tile (corresponding to the wood powder exterior resin floor in the present application) that can be easily constructed on the veranda. There is also a description that the wind speed did not rise even at a wind speed of 40 m / min. Note that this does not indicate that wood flour is included. Furthermore, the cross-sectional shape of the support part which is a part excluding the leg part is a flat plate shape.
[0011]
[Problems to be solved by the invention]
However, in the exterior resin floor of Patent Document 1 as described above, the part that is not pasted even if a decorative sheet is stretched on the surface, that is, the exposed part is exposed to direct sunlight, and the resin base material deteriorates in that part, There is a problem that the cosmetics are markedly deteriorated, and the physical properties thereof are fragile and fragile, and when the flower pot is dropped, it is particularly easy in winter.
[0012]
Therefore, in such a technique, there was a restriction such that it was a use condition that it was not exposed to the sun for use on the veranda.
[0013]
A technique using vinyl chloride resin instead of ABS resin is also conceivable, but this technique has a problem in that dioxin is generated when burned.
[0014]
Therefore, in the present invention, there has been a demand for an exterior resin floor that can be used outdoors, can be used safely even in winter with good impact resistance, is easy to recycle, and has no problem with incineration.
[0015]
Moreover, when an olefin resin base material was simply used as the resin base material, it was difficult to bond the olefin resin decorative sheet to the surface.
[0016]
In addition, in such a packaging resin bed, although in some cases be used in tension-away to fit the floor shape to that used up, it is not easy to cut the desired shape At this time, by the burrs It was not easy to cut the cross section into a clean cross section.
[0017]
Furthermore, it has a cold texture when used outdoors in winter, and since it is not warm, it is practically difficult to use it with bare feet, for example.
[0018]
In this way, a wood powder exterior resin floor that is recyclable, suitable for incineration, suitable for outdoor use, especially in winter, has good impact resistance, has a texture of wood that can be used with peace of mind, and has good machinability is desired. It was.
[0019]
In addition, as the shape of such an exterior resin plate, it was generally convex upward to make it easy to flow rainwater or the like, or at least a flat plate shape, but a typhoon or strong like an airplane wing Uplift is exerted upward by the wind, and there is a problem that it is easily blown away by wind when it is constructed in a high-rise apartment or condominium. An exterior resin plate that does not fly even by typhoons or strong winds has been desired.
[0020]
[Means for solving the problems]
Means for solving the problem in the present invention according to claim 1 is that in the exterior resin floor having at least an olefin resin-based decorative base layer with a surface protective layer on the resin-based base, the resin-based base is The initial flexural modulus was 100 to 50% by weight of an ethylene-propylene copolymer rubber fine particle having an average particle size of 0.1 to 0.5 μm dispersed in 50 to 95% by weight of a homopolypropylene resin containing wood powder. It is intended to provide a wood powder exterior resin floor characterized by comprising a resin having a viscosity of ˜1000 MPa .
[0021]
Since the elongation of the resin was suppressed by the wood flour, no burrs were generated, a clean cut surface was obtained, and the machinability was improved.
[0022]
Moreover, since wood powder was contained, even if both the resin base material and the decorative base material layer were olefin base materials, bonding became easy.
[0023]
In particular, if the resin base material and the decorative base material are aligned with a polypropylene resin, it is easy to recycle because they are the same resin.
[0025]
Incidentally, the olefin resin-based decorative base layer means that a majority of the material of the decorative base layer is made of an olefin resin, and has a secondary layer on the upper surface, the lower surface, or the middle portion, and further on these multiple portions. Even if it contains a secondary composition, the layer or composition does not substantially affect physical properties such as incineration, recycling, impact resistance, and chemical properties such as weather resistance. Yes, it is a layer that can be evaluated as an olefin resin as a whole, and means that at least a part of the layer has wood flour.
[0026]
In this case, “at least” means having a decorative base layer directly or indirectly on the resin base and a surface protective layer on the surface, but the resin base and the decorative base layer are Even if one or more other layers are interposed between the resin base material and the decorative base material layer, one or more other layers are placed under the surface protective layer of the decorative base material layer. Even if it has, it has one or more other layers under the surface protective layer of the decorative base material layer with one or more other layers interposed between the resin base material and the decorative base material layer. It means that you do n’t mind.
[0027]
Further, the surface protective layer means a layer for weather resistance and scratch resistance, but it is preferable that the surface protective layer also serves for wear resistance and gloss adjustment .
[0028]
Because the wood powder suppresses the elongation of the resin, burrs do not occur and a clean cut surface is obtained, and because the wood powder is contained, both the resin base material and the decorative base material layer In both cases, even when the base material is an olefin substrate, the bonding becomes easy.
[0029]
The reason why polypropylene is used for the resin base material is that it has higher heat resistance than polyethylene and polypropylene is often used for the base material of decorative sheets.
[0030]
Means for solving the problem in the present invention according to claim 3 is that in the exterior resin floor having at least an olefin resin-based decorative base layer with a surface protective layer on the resin-based base, the resin-based base is A wood powder exterior resin floor characterized by being a mixture of a polypropylene resin containing wood powder and a polyethylene resin.
[0031]
Because the wood powder suppresses the elongation of the resin, burrs do not occur and a clean cut surface is obtained, and because the wood powder is contained, both the resin base material and the decorative base material layer In both cases, even when the base material is an olefin substrate, the bonding becomes easy.
[0032]
The reason for using a mixture of a polyethylene resin and a polypropylene resin is that the above polypropylene may be preferable while having a melting point lower than that of polypropylene (about 150 ° C.).
[0033]
The means for solving the problems in the present invention according to claim 2 provides a wood powder exterior resin floor , wherein the exterior resin floor has a support portion whose cross-sectional shape is curved downward. To do.
[0034]
With such a structure, even if strong wind blows, the lift works on the lower side, so it is possible to prevent flying from the veranda etc., and special treatment that does not fly, such as connecting to a fence or flying to the end Processing such as attaching preventive members is no longer necessary or necessary.
[0035]
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an exterior resin floor having at least an olefin resin-based decorative substrate layer with a surface protective layer on a resin-based substrate, wherein the resin-based substrate is a wood powder-containing polyethylene resin, polypropylene resin, or a mixture thereof. The present invention provides a wood powder exterior resin floor characterized by a certain thing.
[0036]
In this case, after molding the resin base material by injection molding, etc., the decorative base material layer is laminated by lapping with an adhesive such as a one-component moisture-curing adhesive, or in-mold laminating, transferring or ink jetting at the same time as molding. It is possible to apply makeup.
[0037]
The lapping process is a coating or laminating method for forming the above wrapping structure, specifically, not only pressing the surface with a single roll, but also using an auxiliary roll corresponding to the wraparound part, Soft wrapping that can be applied by pressing even if there is some unevenness using a material that can deform the roll itself even if it is pressed with a single roll. Shall be included.
[0038]
In the present invention, since olefin resins can be easily bonded to each other, lapping is also facilitated.
[0039]
In addition, after extrusion with a profile forming machine, or after extrusion, lapping with a one-component moisture-curing adhesive, it is simply cut into lengths, and further, actual processing and grooving can be processed using a router. .
[0040]
In the present invention, actual machining and grooving may be required as will be described later, but it can be easily performed.
[0041]
The resin base material 1 can use a polypropylene resin containing polyethylene powder, a polyethylene resin, and a mixture of the polypropylene resin and the polyethylene resin.
[0042]
In this case, even if the secondary layer has an upper surface, a lower surface, or an intermediate portion, and further includes a plurality of these components, or those containing a secondary composition, those layers and compositions are incinerated, recycled, It does not substantially affect physical properties such as impact resistance and chemical properties such as weather resistance, and can be evaluated as polypropylene resin containing polyethylene powder, polyethylene resin, and a mixture of this polypropylene resin and polyethylene resin as a whole. It is a matter of course that a small number of modifications may be made as long as it is.
[0043]
For example, an ethylene-propylene copolymer having an average particle size of 0.1 to 0.5 μm is added to 50 to 95% by weight of a homopolypropylene resin in order to soften the base material and to provide further impact resistance. A configuration in which rubber fine particles are dispersed in an amount of 5 to 50% by weight is also possible. In this case, since the initial elastic modulus is 100 to 1000 MPa, the walking feeling is improved.
[0044]
In addition, as for the machinability, just having wood powder does not generate burrs because the elongation of the resin is simply suppressed, and a clean cross section can be obtained, but in reality this increases the rigidity, and when it is used, it becomes a floor shape In some cases, it may be cut and used together, but at this time, it is not easy to cut into a free shape, and the cutting performance may not be sufficient, but this configuration further improves the cutting performance.
[0045]
In addition, in such an exterior resin floor, it may be cut and used in accordance with the floor shape at the time of use, but at this time, it is not easy to cut out, and the cost of the construction work is increased and the construction period is long. It has become possible to adopt a configuration that can solve the problems that are not easy to cut into a free shape because it is necessary to use a saw or the like because it is stretched, labor is required, or a saw is used.
[0046]
Furthermore, even if the surface temperature reaches about 60,70 ° C. due to direct sunlight in midsummer, the thermal shrinkage is absorbed, so that the dimensional stability is increased. In addition, the elastic action of the ethylene-propylene copolymer rubber fine particles provides an appropriate elasticity even in the severe winter season, and further, an appropriate elasticity can be maintained even under direct sunlight in the summer due to the entropy elasticity.
[0047]
In addition, as a method of putting wood flour, wood flour is put by a well-known method.
[0048]
Although the decorative base material layer 8 is provided on the upper part of the resin base material 1, since the joint part and the real part are exposed to direct sunlight, it is preferable to apply a weather resistance prescription to the resin base material 1.
[0049]
When blended with an ultraviolet absorber, general-purpose benzotriazole (basic skeleton absorption maximums of around 300 nm and 340 nm), benzophenone based on compatibility with the resin (basic skeleton absorption maximums of around 290 nm and 330 nm), triazine System (basic skeleton absorption maximums around 280 nm and 340 nm), ogizanide, salicylate, cyanoacrylate, etc., light stabilizer (hindered amine light stabilizer etc.), etc. are possible. The amount is preferably about 0.1 to 5 parts by weight.
[0050]
Furthermore, you may add antistatic agents, such as a well-known heat stabilizer, anti-algae, an antifungal agent, and a quaternary ammonium salt. Moreover, in order to improve the adhesiveness with the decorative substrate layer, the surface after molding may be subjected to corona treatment, plasma treatment or the like.
[0051]
The cross-sectional shape of the support portion of the resin base material 1 is desirably a shape in which the central portion is curved downward .
[0053]
FIG. 3 shows a conceptual diagram of a shape curved downward in a convex shape . Although this shape makes it difficult for rainwater or the like to flow, measures can be taken by actual machining or groove machining.
[0054]
For the decorative base layer 8, polyolefin resins such as polypropylene resins and polyethylene resins, and mixtures thereof can also be used.
[0055]
For example, the decorative base layer 8 may be configured by a colored lower base layer 3, a pattern ink layer 4, an anchor agent layer 5, a transparent upper base 6, and a surface protective layer 7.
[0056]
As the colored lower layer 3, a known colorant, ultraviolet absorber, light stabilizer, etc. are added to the homopolypropylene resin. The thickness is preferably about 60 μm to 150 μm, but is preferably 70 μm or more in consideration of concealment and the like. As the ink for the pattern layer, a two-component curable urethane resin system is desirable from the viewpoint of adhesion strength. It is desirable that the surface tension be 38 mN / m to 55 mN / m by corona treatment on both sides. It is desirable to apply a coating amount of 0.5 to ² g / m ² after drying silica and a two-component curable urethane resin-based primer on the back surface.
[0057]
As the transparent upper base 6, as long as it is a transparent polyolefin resin, polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α Olefin copolymers, ethylene-ethyl acrylate copolymers, acid-modified products thereof, ionomers, and the like are desirable.
[0058]
The surface protective layer 7 may be applied by adding an ultraviolet absorber and a light stabilizer to a two-component urethane-bonded acrylic urethane resin composed of acrylic polyol and isocyanate, and applying a coating amount after drying of 5 to 10 g / m ^2. Conceivable.
[0059]
The anchor agent 5 may be provided later. In this case, it is desirable to apply a two-component curable urethane resin in an application amount of 0.5 to 2 g / m 2 after drying.
[0060]
In addition, when bonding the resin-type base material 1 and the decorative base material layer 8 using a wrapping machine, it is preferable to laminate, extruding the reactive hot-melt adhesive 9 at a temperature thickness of about 120 ° C. and about 50 to 150 μm.
[0061]
【Example】
Example 1
The resin-based substrate 1 has a mean particle size of 0.1% in 50% by weight of a commercially available homopolypropylene resin (bending elastic modulus 1500 Mp) in order to soften the substrate and make it flexible and further have impact resistance. 50% by weight of homopolypropylene resin (Cataloy KS081P manufactured by Sun Allomer Co., Ltd.) in which 50% by weight of 2-0.3 μm ethylene-propylene copolymer rubber fine particles are dispersed, 100% by weight of homopolypropylene resin having an initial flexural modulus of 500 MPa, and an average particle diameter After pelletizing 100 μm wood filler, the support part was extruded into a shape as shown in FIG. 3 with a single screw extruder, and legs were added by a method of router processing in the lateral direction.
[0062]
In addition, a benzotriazole type (absorption maximum of 300 nm and around 340 nm of the basic skeleton) ultraviolet absorber as a weather resistance prescription is added to the resin base material 1 in an amount of 0.5 parts by weight, and further, a known heat stabilizer, Antistatic agents such as algae, fungicides and quaternary ammonium salts were added. Moreover, in order to improve the adhesiveness with the decorative base material layer, the surface after molding was subjected to corona treatment to make the surface 48 mN / m.
[0063]
Furthermore, a known colorant, an ultraviolet absorber, a light stabilizer and the like were added to the homopolypropylene resin as the colored base layer 3 of the decorative base layer 8. The thickness is 70 μm. As the ink for the pattern layer, a wood grain pattern was printed with a two-component curable urethane resin system (manufactured by Toyo Ink Manufacturing Co., Ltd.). The back surface of the colored lower layer 3 was applied with a coating amount of 0.5 to ² g / m ² after drying silica and a two-component curable urethane resin-based primer.
[0064]
The transparent upper base 6 is co-extruded with an adhesive resin of maleic acid-modified polyolefin resin at a ratio of 95 parts by weight of IPP (isotactic polypropylene resin) and 5 parts by weight of APP (atactic polypropylene resin) and 80 μm. 6 was obtained.
[0065]
For the surface protective layer 7, an ultraviolet absorber and a light stabilizer are added to a two-component urethane-bonded acrylic urethane resin composed of acrylic polyol and isocyanate, and the coating amount after drying is applied at 8 g / m ² .
[0066]
The anchor agent 5 was applied as a coating amount of 1 g / m ² after drying a two-component curable urethane resin.
[0067]
Next, while extruding with a profile forming machine, one-component moisture curing reaction type adhesive (YR210-3 manufactured by Hitachi Chemical Polymer Co., Ltd. was extruded at 120 ° C. and 100 μm thick and lapped, and then cut into a length of 600 mm. The actual machining and grooving were processed into a shape using a router.
[0068]
( Reference Example 1 )
The same wood powder exterior resin bed as in Example 1 was used except that a polyethylene resin was used instead of the polypropylene resin in Example 1 .
[0069]
( Example 2 )
Other convexly curved cross-sectional shape of the wood flour resin substrate of Example 1 above were the same wood flour packaging resin bed as in Example 1.
[0070]
[Table 1]

[0071]
Table 1 shows the wind speed test.
[0072]
【The invention's effect】
Recycling is easy because it is mainly made of olefin resin. In particular, if the resin base material and the decorative base material are aligned with a polypropylene resin, it is easy to recycle because they are the same resin.
[0073]
In addition, even if it is difficult to recycle, incineration no longer causes problems.
[0074]
Moreover, since weather resistance is good, it may be used for a stepping stone in a garden other than a veranda which has a slow outdoor deterioration and improved impact resistance as a countermeasure against falling objects.
[0075]
In the invention of the present application, it is also possible to produce by a profile forming machine. In this case, while extruding or extruding, further lapping with a one-component moisture-curing adhesive and further cutting into unit lengths, Furthermore, actual processing and grooving can be performed using a router, which can improve mass productivity while maintaining drainage.
[0076]
It is also possible to blend ethylene-propylene copolymer rubber fine particles. In this case, for example, ethylene-propylene copolymer rubber fine particles having an average particle size of 0.1 to 0.5 μm in 50 to 95% by weight of homopolypropylene resin. If the composition is such that 5 to 50 parts by weight is mixed, the machinability and the feeling of walking are improved, and the thermal stability is absorbed even when the surface temperature reaches about 60 or 70 ° C. due to direct sunlight in midsummer. Increase.
[0077]
Moreover, due to the excellent elastic action of the ethylene-propylene copolymer rubber fine particles, there is moderate elasticity even in the severe winter season, and furthermore, moderate elasticity can be maintained even under direct sunlight in midsummer due to the entropy elasticity.
[0078]
Since the shape of the support part is convex downward, lift will work downward and it will be difficult to turn over even in a typhoon, etc., and in this case there will be a gap between the enforcement surface and the support part, so on the enforcement surface such as a veranda On the other hand, it was easy to renovate because it was easy to construct.
[Brief description of the drawings]
FIG. 1 is a partial schematic cross-sectional view of an embodiment of a wood powder exterior resin plate of the present invention.
2 is an overall schematic cross-sectional view of one embodiment of FIG. 1; (However, the primer layer and reactive hot melt adhesive are omitted)
FIG. 3 is a conceptual cross-sectional view of a curved shape protruding downward from the wood powder exterior resin floor of the present invention.
FIG. 4 is an explanatory view of an airfoil of a wood powder exterior resin floor of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Resin-type flooring material 2 Primer layer 3 Colored lower base 4 Picture ink layer 5 Anchor agent layer 6 Transparent upper base 7 Surface protective layer 8 Cosmetic base material layer 9 Reactive hot melt adhesive

Claims (2)

In an exterior resin floor having at least an olefin resin-based decorative substrate layer with a surface protective layer on a resin-based substrate, the resin-based substrate is an average of 50 to 95% by weight of a homopolypropylene resin containing wood flour. A wood powder exterior resin bed comprising an ethylene-propylene copolymer rubber fine particle having a particle size of 0.1 to 0.5 μm and a resin having a flexural initial elastic modulus of 100 to 1000 MPa dispersed therein. . 2. The wood powder exterior resin floor according to claim 1, wherein the exterior resin floor has a support portion whose cross-sectional shape is curved downward .

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